The fast-growing e-mobility market places high demands on battery cell production in terms of speed and efficiency. This is why intelligent, high-performance automation solutions are so essential. Our control technology enables end-to-end automation of all processes in battery manufacturing: from electrode production to module and pack assembly. PC-based control offers advantages for all machine types, no matter whether you produce round, pouch, or prismatic battery cells. We offer the perfect solutions for all forms of battery technology too: from lithium-polymer cells to solid-state battery cells to LFP cells.
Your head start in battery manufacturing with Beckhoff:
- high speed thanks to fast cycle times
- optimal synchronization of control functions on a single platform
- execution of sophisticated motion tasks
- flexible scalability of hardware and software
Control technology for all battery manufacturing processes
PC-based control optimizes all production steps:
High-precision battery cell winding
The rolling process used in round cell production involves winding a jelly roll from an anode strip, a cathode strip, and two separator strips. This calls for exceptional precision and speed.
Our approach involves the use of a central PC-based automation platform to achieve maximum process efficiency in battery cell winding, as this allows vision systems, motion tasks, and communication to I/Os to all be controlled with a high level of synchronicity. It also enables precise winding accuracy while maintaining high output.
Our product highlights for the winding process:
- Vision portfolio: Image processing synchronizable with all control processes
- TwinCAT Motion Control: Modular software solution for complex motion profiles – e.g., rapid and accurate synchronization of continuous to clocked processes
- Distributed drive technology: Servomotors with integrated servo drive
- EtherCAT high-speed fieldbus with exact timestamp function
Quick and accurate stacking of battery cells
Pouch cells are produced in a stacking process: Electrode sheets of cathode or anode material are placed between separator layers – for example, with a Z-fold. Similar to the winding process for round cells, a high level of accuracy and speed are crucial in Z-folding.
With our modular TwinCAT automation software, even very complex motion tasks in the stacking process of battery cells can be executed with real precision. This makes it possible to control up to 255 axes synchronously. On the hardware side, a large portfolio of drive technology is available in various performance classes.
Our product highlights for the stacking process:
- TwinCAT Motion Control: Synchronous control of up to 255 axes, along with the integration of robot kinematics
- Compact drive technology: Motion solutions for operation in even the smallest of installation spaces
- XPlanar: Floating planar motor system for the transport or stacking process
Ensure safe electrolyte filling with components for explosion protection
Once the wound or stacked battery cells have been placed in their packaging, they are filled with the electrolyte. In addition to precise metering of the electrolyte liquid, adequate safety measures with regard to explosion protection play a major role in this process step.
We also offer integrated automation solutions for hazardous areas: Process technology requirements can be implemented directly via the central control platform and integrated into real-time applications. An extended product range is available for use in potentially hazardous areas.
Our product highlights for electrolyte filling:
- ELX terminals: Direct connection of intrinsically safe field devices from zone 0/20
- CPX series: Elegant control panels and panel PCs for use in zone 2/22
- Embedded PCs and bus couplers: System control and communication in zone 2/22
Flexible solutions for cell transport
For the initial charging and discharging processes and further cell aging, the battery cells are transported to various shelf storage systems after the electrolyte filling process. This primarily relies on roller conveyors and AGVs.
When it comes to controlling motor-driven roller conveyor systems, we offer a compact and seamlessly integrated solution in the form of the EP7402 EtherCAT Box. What’s more, our XTS and XPlanar intelligent transport systems allow you to completely rethink existing transport processes and design them with total flexibility.
Our product highlights for cell transport:
- EP7402 EtherCAT Box: Compact controller for motor-driven roller conveyor systems
- XTS with NCT: Enables handling and quality control during transport
- XPlanar: Floating product transport with maximum flexibility
Powerful robotics solutions for module and pack assembly
Batteries used in electric cars are first assembled into modules after production and then into larger battery packs. During module assembly, the individual battery cells have to be glued and welded together within a very short time. This is where precise robotics solutions are required for accurate and fast positioning.
TwinCAT enables the implementation of all common robot kinematics via modular software blocks: Direct integration into the control platform ensures maximum performance and efficiency.
Our product highlights for battery module assembly:
- TwinCAT Kinematic Transformation: Integrates all common robot kinematics into the TwinCAT control platform
- Highly dynamic servomotors for delta pickers or portals
- One Cable Technology: Reduces installation and cabling costs when connecting servomotors
- ATRO: Modular industrial robot system with standardized interfaces
Visual inspection of battery cells with efficient vision technology
Each manufactured battery cell is affixed with a barcode or QR code to facilitate clear identification of the manufactured battery cells in the future. A visual inspection at the end of the production process ensures that all cells are ultimately checked and labeled. This typically occurs during cell transport.
The complete Beckhoff vision system enables image processing to be integrated into the control platform. The use of the XPlanar system also increases traceability, as the data from image processing can be combined with the position data from the XPlanar movers.
Our vision system for the final quality control:
- Complete hardware portfolio: Cameras, illuminations, and units for image capture
- TwinCAT Vision: Integrates image processing seamlessly into the TwinCAT control platform
- Full integration into EtherCAT supports real-time applications
High-precision measurement technology for testing battery packs
Once the individual battery cells are assembled into modules, and these modules into packs, it is essential to measure the electrical and thermal properties of the entire system. For example, the temperature of the individual packs is checked while the battery cells go through several charging cycles.
All common sensors can be integrated via the Beckhoff I/O modules. In this way, measurement tasks are integrated directly into the control system. The EtherCAT measurement terminals in the ELM series provide a broad portfolio for high-precision data acquisition.
Our measurement technology for all inspection and testing tasks:
- ELM3002-0205 facilitates high-voltage measurement on batteries and generators
- ELM3348-0003 is designed for high-precision temperature measurement with thermocouples
- Extensive portfolio of measurement terminals from the ELM series for other measurement tasks
- Integration of external measuring devices via corresponding communication terminals
Implemented worldwide: Beckhoff in battery manufacturing and e-mobility
Automation for highly precise and efficient production of lithium-ion battery modules
The rapidly growing electromobility market calls for particularly efficient manufacturing processes when it comes to the production of lithium-ion battery systems. This is where the BLS 500 laser welding system from Manz makes for an ideal solution, as it allows individual battery cells to be precisely contacted and connected to form battery modules. A high level of efficiency is ensured by means of a graphical programming tool and a virtual commissioning tool from Manz, as well as rapid PC-based control technology from Beckhoff and the continuous OPC UA communication this facilitates.
Linear transport system eliminates slow pick-and-place process
Low-cost lithium-ion battery cells (LIB) are the key to mass electromobility, although the manufacturing process has always been a cost driver – until now. Researchers at TU Berlin are using continuous Z-folding to replace the traditional pick-and-place movements that have been used so far, thereby accelerating battery cell production. The XTS linear transport system from Beckhoff has played a crucial role here.
Reliable and efficient operation due to fast and powerful control technology
Chinese automaker NIO aims to provide high-quality smart electric vehicles combined with an optimal user experience. The NIO Power energy service system makes a valuable contribution in this regard, using PC-based control from Beckhoff to ensure safe and efficient operation of NIO’s second-generation battery swap stations.
Special purpose automation solutions for the automotive and battery industries
S4 Integration, a South African company, provides special purpose end-to-end solutions in industrial automation and software for the automotive and energy storage industries. Shaun Erasmus, their customer engagement manager, discusses their work with Beckhoff in this video.
Further information
Automotive industry
PC-based control from Beckhoff supports modern manufacturing concepts for the mobility of the future.
Assembly and handling technology
PC-based control technology from Beckhoff optimizes the entire process chain: from handling, production, and assembly to testing, control, and management.